Protected underwire

ABSTRACT

In a first embodiment, a first fabric layer has gelatinous strips, thereby separating the first fabric layer into sections. A second fabric layer is positioned upon the first fabric layer, and an underwire is positioned on the second fabric layer opposite the first fabric layer. The first fabric layer is then folded onto itself to enclose the second fabric layer and the underwire. In a second embodiment, a third, or intermediate, fabric layer is positioned between the first and second fabric layers. In a third embodiment, an underwire is surrounded by a first, non-woven fabric layer. A second, rigid-type fabric having a bladder with a gelatinous material is positioned on the first fabric. The first fabric is wrapped around the underwire, and the bladder is positioned against the body of the wearer.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.10/313,992 filed Dec. 26, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to brassieres. More particularly, thepresent invention relates to a protected brassiere underwire and methodof making the same.

2. Description of the Related Art

The use of underwire elements, especially U-shaped underwires, forshaping and supporting the lower periphery of brassiere or bra cups haslong been known in the art. The term “underwire” has been in common useto refer to such elements. An underwire includes metal wires, coatedmetal wires, as well as wire elements made of many different materials,such as plastic or other polymeric materials. These underwires must berigid enough, particularly in the plane of the brassiere, to provideadequate support for the bust and yet flexible enough to conform easilyto the wearer's body for comfort and appearance. Such underwires areprovided in a variety of shapes and configurations and must satisfy anumber of requirements. For example, the underwire must not poke throughthe fabric to cause damage to the clothing of the wearer, and possiblyinjury to the wearer. It also must be readily insertable. Commonly, suchunderwires have been inserted into fabric sleeves disposed about thelower periphery of the bra cups.

Modern underwires are generally formed of relatively thin lengths ofmetal or polymeric material having a rectangular or roundedcross-section. A fairly stiff length of such material is shaped into ageneralized U-shape and positioned in a sleeve disposed about the lowerperiphery of each bra cup. These stiff metal underwires are sometimescoated with various polymeric materials and often have plastic or enameltips disposed at each end of the underwire.

While underwires have achieved widespread usage, certain disadvantagesresult from their use. These disadvantages relate to the relativestiffness, and therefore discomfort of these conventional underwires,and to the uniformity of that stiffness and, thus, the lack ofadaptability to the needs of various users.

In light of the foregoing, there is an ongoing need for underwires orunderwire structures, that are comfortable to wear, resilient, andadequately support the breasts of the wearer.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a cushion feelunderwire or underwire structure.

It is an another object of the present invention to provide such anunderwire structure that has a greater cushioning ability or greater“loft” than the underwire structures of the prior art.

It is still another object of the present invention to provide such anunderwire structure that avoids having a thick appearance and/or a stifffeel.

It is yet another object of the present invention to provide such anunderwire structure that can be used in a number of different sizedbrassieres.

It is a further object of the present invention to provide such anunderwire structure that is particularly comfortable to wear, and can beconveniently assembled in the brassiere.

It is still a further object of the present invention to provide such anunderwire structure that has its own casing.

These and other objects and advantages of the present invention areachieved by the underwire structure of the present invention. In a firstembodiment, there are provided two or more outer fabric layers. Theouter fabric layers each have gelatinous strips associated therewith.The gelatinous strips separate the outer fabric layers into sections. Aninner fabric layer is positioned upon the gelatinous strips of the firstouter fabric layer. This inner fabric layer is preferably non-woven. Anunderwire is positioned on the inner fabric layer opposite the outerfabric layer. The outer fabric layers are then folded to enclose thegelatinous strips, the inner fabric layer and the underwire. Thus, theunderwire is enclosed in a casing formed by the outer fabric layers.Once the outer fabric layers are folded, a fold line is created.

In a second embodiment, there is provided four fabric layers and anunderwire. As in the first embodiment, the first and second outer fabriclayers each have at least one surface with gelatinous strips, therebyseparating the surface and/or outer fabric layer into sections. Thesecond outer fabric layer forms an outside covering for the underwire.As in the first embodiment, an inner fabric layer is positioned on theunderwire to form an inside covering for the underwire. The inner fabriclayer is preferably non-woven. An intermediate fabric layer ispositioned between the first outer and inner fabric layers to form asecond interior covering for the underwire. The underwire is positionedon the inner fabric layer opposite the intermediate fabric layer. Thesecond and first outer fabric layers are folded to enclose the inner andintermediate fabric layers and the underwire. Thus, the underwire isencased by all four fabric layers. In this second embodiment, a foldline is knitted into the second outer fabric layer and first outerfabric layer prior to folding.

In a third embodiment, there is also provided an underwire. Theunderwire is surrounded by a non-woven fabric layer. A bladdercontaining a gelatinous material is encased by a rigid-type fabric. Thebladder is positioned on the non-woven fabric layer opposite theunderwire. The purpose of the non-woven fabric is to reduce the risk ofthe underwire poking through the rigid fabric encasing the bladder. Thebladder is preformed or pre-made into a preshaped configuration. Thefabric encasing the bladder is preferably a rigid fabric. Morepreferably, the fabric encasing the bladder is a tricot or warp knitfabric. The non-woven fabric is wrapped around the underwire, and thebladder is positioned against the body fabric that forms the breast cupof the brassiere.

In all embodiments, the non-woven fabric layer may also be made of astretchable material.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and advantages of the present invention will be moreapparent from the following detailed description of the presentinvention, in conjunction with the accompanying drawings wherein:

FIG. 1 is a schematic drawing showing a first embodiment of the presentinvention;

FIG. 2 is a magnified view of the stretch fabric used for any of theouter layers in the first embodiment of the present invention;

FIG. 3 is a schematic drawing showing an alternative to the firstembodiment of the present invention;

FIG. 4 is a schematic drawing showing a second alternative to the firstembodiment of the present invention;

FIG. 5 is a schematic drawing showing a second embodiment of the presentinvention;

FIG. 6 is a schematic drawing showing an alternative to the secondembodiment of the present invention; and

FIG. 7 is a schematic drawing showing a third embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, and in particular, FIG. 1, there is provideda first embodiment of an underwire structure of the present inventiongenerally represented by reference numeral 10. Underwire structure 10has a first outer layer of material 20 upon which a first gelatinousmaterial 50 is applied. Underwire structure 10 also has a second outerlayer of material 70 upon which a second gelatinous material 75 isapplied. It should be noted that, while first and second outer materiallayers are preferred, multiple layers may be employed to provideenhanced cushioning effect. Gelatinous materials 50 and 75 arepreferably applied in one or more strips to first outer material layer20 and second outer material layer 70. However, it should be noted thatgelatinous materials 50 and 75 may be applied in any manner known in theart. Non-limiting examples include sinusodial, dashed or dottedpatterns. An inner layer of material 30 is positioned adjacent togelatinous material 50 on first outer material layer 20, and anunderwire 40 is positioned on or adjacent to inner material layer 30opposite first outer material layer 20.

As shown in FIG. 2, outer material layers 20 and 70 (outer layer 20represented) preferably have two strips of gelatinous material 50 placedthereon. Accordingly, the outer material layers preferably have threeregions that are not covered by gelatinous material 50. These threeregions are two sew regions or edges 24, and a fold line or third sewregion 28. Fold line 28 is located along the center of outer materiallayer 20.

Referring again to FIG. 1, second outer material layer 70 withgelatinous material 75 is adjacent to first outer material layer 20 withgelatinous material 50. First outer material layer 20 with gelatinousmaterial 50 is also adjacent to inner material layer 30 with one side ofinner material layer 30 contacting gelatinous material 50. Second outermaterial layer 70, gelatinous material 75, first outer material layer20, gelatinous material 50 and inner material layer 30 are wrappedaround underwire 40. A body fabric 60 is positioned on a side ofunderwire 40 opposite inner material layer 30. Second outer materiallayer 70 with gelatinous material 75 and first outer material layer 20with gelatinous material 50 provide a cushioned feel and loft aboutunderwire 40 thereby making the underwire structure more comfortable forthe wearer. Inner material layer 30 prevents underwire 40 from-pokingthrough outer material layer 20.

During assembly, second outer material layer 70 and first outer materiallayer 20 are positioned adjacent to one another. Inner material layer 30is positioned adjacent to gelatinous material 50 of outer material layer20. Underwire 40 is positioned on or adjacent to inner material layer 30opposite outer material layer 20. Body fabric 60 is positioned on oneside of underwire 40 opposite inner material layer 30. Preferably, aportion of body fabric 60 is positioned on one side of underwire 40 suchthat body fabric 60 is in the same plane as underwire 40. Second outermaterial layer 70 and first outer material layer 20 are then foldedabout fold line 28 to enclose gelatinous material 75, gelatinousmaterial 50, and inner material layer 30 about the end of body fabric 60and underwire 40. When outer material layer 20 and inner material layer30 are folded along fold line 28, a channel is created for underwire 40.Thus, in this embodiment, a casing for underwire 40 is formed by secondouter material layer 70, gelatinous material 75, first outer materiallayer 20, gelatinous material 50 and inner material layer 30. In thefirst embodiment shown in FIG. 1, the underwire casing is sealed usingsingle needle stitching.

Body fabric 60 may be positioned in alternative locations in relation tounderwire structure 10. Referring to FIG. 3, body fabric 60 may bepositioned such that it is not in the same plane as underwire 40.Instead, when second outer material layer 70 and first outer materiallayer 20 are folded, body fabric 60 is sandwiched directly between theends of second outer fabric layer 70 and does not come into contact withunderwire 40.

Referring to FIG. 4, body fabric 60 may be connected to second outermaterial layer 70 at an upper edge of underwire structure 10. This typeof underwire casing is sealed using double needle stitching.

In a second embodiment of the present invention, shown in FIG. 5,underwire structure 10 has at least four layers of material, secondouter material layer 70, first outer material layer 20, an innermaterial layer 30 and an intermediate material layer 25 positionedbetween first outer material layer 20 and inner material layer 30, andan underwire 40 positioned on inner material layer 30 oppositeintermediate material layer 25. Gelatinous material 50 is placed on aninterior surface of first outer material layer 20. Gelatinous material75 is placed on an interior surface of second outer material layer 20.Second outer material layer 70 forms an outside covering aroundgelatinous material 75, first outer material layer 20, gelatinousmaterial 50, intermediate layer 25, inner material layer 30 andunderwire 40.

Inner material layer 30 is positioned on underwire 40 to form an insidecovering for the underwire. The function of inner material layer 30 isto prevent underwire 40 from poking through the other layers ofmaterial.

Intermediate material layer 25 is positioned between outer materiallayer 20 and inner material layer 30 to form a second interior coveringfor underwire 40. Body fabric 60 is preferably positioned on one side ofunderwire 40 opposite inner material layer 30. The positioning of bodyfabric 60 in FIG. 5 is analogous to the positioning shown in FIG. 1 inthat a portion of the body fabric is in the same plane as underwire 40.

Second outer material layer 70 and first outer material layer 20 arefolded about fold line 28 to enclose inner material layer 30 andintermediate material layer 25 about the end of body fabric 60 andunderwire 40 creating a multi-layer underwire channel for housing theunderwire. Thus, in this embodiment, a casing for underwire 40 is formedby second outer material layer 70, gelatinous material 75, first outermaterial layer 20, gelatinous material 50, intermediate material layer25 and inner material layer 30. In this embodiment, stitching,preferably, single needle stitching, is used to seal the casing.

As discussed with reference to FIGS. 3 and 4, body fabric 60 may bepositioned in alternative locations in relation to underwire structure10. As shown in FIG. 6, body fabric 60 is positioned such that it is notin the same plane as underwire 40. Instead, when second outer materiallayer 70 and first outer material layer 20 are folded, body fabric 60 issandwiched directly between the ends of intermediate fabric layer 25. Inanother alternative, body fabric 60 is connected to second outermaterial layer 70 at an upper edge of underwire structure 10. As in FIG.4, this type of casing is sealed utilizing stitching, preferably doubleneedle stitching.

Second outer material layer 70 and first outer material layer 20 arepreferably made of a stretchable material. More preferably, second outermaterial layer 70 and first outer material layer 20 are made of a threebar powernet knit. Second outer material layer 70 and first outermaterial layer 20 may be made of varying combinations of nylon andspandex. The percentage of nylon ranges from about 78% to about 84%based on fabric content, while the percentage of spandex ranges fromabout 16% to about 22% based on fabric content. Preferably, second outermaterial layer 70 and first outer material layer 20 are made of about81% nylon and about 19% spandex. Second outer material layer 70 andfirst outer material layer 20 are lightweight, ranging from about 5ounces per yard squared (oz/yd²) to about 5.8 oz/yd². The tensile lengthof second outer material layer 70 and first outer material layer 20 isminimally about 25 pounds (lbs.), while the tensile width of secondouter material layer 70 and first outer material layer 20 is minimallyabout 33 lbs.

Gelatinous material 75 and 50 is preferably silicone. However, anyliquid material can be used that is safe for contact with a wearer andhas a soft feel. Gelatinous material 75 and 50 is applied on secondouter layer 70 and first outer material layer 20 in strips or tracks.Preferably, gelatinous material 75 is about 56% of the overall weight ofthe combination of outer material layer 70 and gelatinous material 75.Preferably, gelatinous material 50 is about 56% of the overall weight ofthe combination of outer material layer 20 and gelatinous material 50.The height or thickness of the strips of gelatinous material 75 and 50ranges from about 0.02 inches to about 0.03 inches. The width of thesestrips ranges from about {fraction (3/16)} inches to about ¼ inches. Thewidth between the strips ranges from about {fraction (1/16)} inches toabout ⅛ inches. The width of sew region 24 ranges from about ⅛ inches toabout {fraction (3/16)} inches.

Inner material layer 30 is preferably made of a non-woven,non-stretchable fabric material. However, inner material layer 30 may bemade of a stretchable material. Inner material layer 30 is preferablymade of polyester. More preferably, inner material layer 30 is made of100% polyester. Inner material layer 30 is lightweight, preferably about5 oz./yd²±10%. The burst strength of inner material layer 30 isminimally about 110 lb. per square inch. The tensile strength of innermaterial layer 30 is minimally about 55 lbs. The preferred thickness ofinner material layer 30 falls in the range of about 0.53 mm to about0.84 mm. Inner material layer 30 is sold commercially under the nameTIETEX® by Tietex International Ltd.

Intermediate material layer 25 is a preferably a woven, non-stretchablematerial. However, intermediate material layer 25 may be made of astretchable material. More preferably, intermediate material layer 25 isa nylon taffeta. Intermediate material layer 25 is also lightweight,ranging from about 1.8 oz/yd² to about 2.2 oz/yd². The tensile length ofintermediate material layer 25 is minimally about 70 lbs., while thetensile width of intermediate material layer is minimally about 60 lbs.

It should be understood that these dimensions may vary depending uponthe desired criteria for each group of potential customers.

In either embodiment, an important aspect of the present invention isthat the casing of the underwire preferably be stretchable. However, itmay be non-stretchable.

Referring to FIG. 7, there is provided a third embodiment of theunderwire structure of the present invention generally represented byreference numeral 100. Underwire structure 100 includes a two plystructure that has a bladder 110 having a gelatinous material placed inor on a layer of a first fabric 140. The gelatinous material ispreferably silicone, but may be any type of liquid material that is safefor contact with a wearer and has a soft feel. This structure is placedon a layer of a second fabric 120, and an underwire 130. In thisembodiment, only second fabric layer 120 is wrapped around underwire130. First fabric layer 140 with bladder 110 is positioned on the secondfabric layer 120/underwire 130 structure with bladder 110 positionedagainst a body fabric 160 and opposite a garment or outer brassierelayer 170. In this embodiment, double needle stitching is preferablyused to seal the casing. First fabric layer 140 is a rigid fabric, suchas a tricot or warp knit fabric, which does not stretch.

Significantly, the bladder configuration can fit a number of differentunderwire sizes. Preferably, one bladder will fit at least three sizesof underwires.

In all embodiments of the present invention, each end of the underwireoptionally may have a protective tip positioned thereon. In addition,the wire casing or channel must have enough room at its ends to avoidpoke-through of the underwire.

The present invention provides underwire structures that have theunderwire encased by a gelatinous material. These structures provide acushiony feel, yet are not thick or bulky. Moreover, the cushiony feelis so pronounced that there is a loft created so that the wearer has asoftness and pliability, yet the desired support under the breast area.

The present invention having been described with particular reference tothe preferred forms thereof, it will be obvious that various changes andmodifications may be made without departing from the spirit and scope ofthe invention as defined herein.

1. A cushioning structure for an underwire of a brassiere, comprising: afirst layer of fabric disposed about at least a portion of saidunderwire; a first gelatinous material between said first layer and saidunderwire; a second layer of fabric disposed about at least a portion ofsaid first layer of fabric; and a second gelatinous material betweensaid first layer of fabric and said second layer of fabric.
 2. Thecushioning structure of claim 1, further comprising an inner layer offabric between said first gelatinous material and said underwire.
 3. Thecushioning structure of claim 2, wherein said first and said secondlayer of fabric is made of a non-woven, non-stretchable material.
 4. Thecushioning structure of claim 1, further comprising a fourth layer offabric between said gelatinous material and said second layer.
 5. Thecushioning structure of claim 4, wherein said fourth layer is a woven,non-stretchable material.
 6. The cushioning structure of claim 1,wherein said second outer layer and said first outer layer are folded toenclose said first and second gelatinous material and said underwire. 7.The cushioning structure of claim 1, wherein one of said first andsecond gelatinous materials is silicone.
 8. The cushioning structure ofclaim 1, wherein said underwire has a first end and a second end, andwherein each of said first and second ends has a protective tippositioned thereupon.
 9. The cushioning structure of claim 1, whereinsaid inner layer is made of a stretchable material.
 10. The cushioningstructure of claim 1, wherein said inner layer is made of a three barpowernet knit.
 11. The cushioning structure of claim 1, wherein saidinner layer is made of a combination of nylon and spandex.
 12. Thecushioning structure of claim 1, wherein said inner layer is about 78%to about 84% nylon.
 13. The cushioning structure of claim 1, said innerlayer is about 16% to about 22%.
 14. The cushioning structure of claim1, wherein said inner layer is about 81% nylon and 19% spandex.
 15. Thecushioning structure of claim 2, wherein-said first and second outerlayers are made of polyester.
 16. The cushioning structure of claim 2,wherein said first and second outer layers are made of 100% polyester.17. The cushioning structure of claim 3, wherein said fourth layer ismade of nylon taffeta.
 18. A cushioning structure for an underwire of abrassiere, comprising a composite structure having at least two layersof fabric and at least two layers of a gelatinous material, saidcomposite structure having an overall weight, wherein said at least twolayers of gelatinous material has a weight of about 56% of said overallweight.
 19. A method of forming a cushioning structure comprising thesteps of: applying a first gelatinous material to a side of a firstlayer of material; applying a second gelatinous material to a side of asecond layer of material; positioning said second layer of material withsaid second gelatinous material on said first layer of material withsaid first gelatinous material; positioning an inner layer of materialon said first gelatinous material opposite said first layer of material;positioning an underwire upon said inner layer opposite said gelatinousmaterial; folding said second outer layer and said first outer layerabout a fold line to enclose said second gelatinous material, said firstgelatinous material, said inner layer of material and said underwirethereby forming a casing; and sealing said casing along an upper edge ofsaid second outer layer of material opposite said fold line.